Komatsu Hydraulic Excavator GALEO PC400LC-E0 Series Repair Service Manual + Operation Maintenance Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator GALEO PC400LC-7E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator GALEO PC400LC-7E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,185 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM017001 - Hydraulic Excavator GALEO PC400LC-7E0 Operation & Maintenance Manual.pdf
CEBM016902 - Hydraulic Excavator GALEO PC400LC-7E0 Shop Manual.pdf
MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
FOREWORD...3
SAFETY...11
SAFETY NOTICE...11
GENERAL...13
HOW TO READ THE SHOP MANUAL...14
HOISTING INSTRUCTIONS...15
PUSH PULL COUPLER...16
EXPLANATION OF MAINTENANCE STANDARD TERMS...19
STANDARD TIGHTENING TORQUE...21
BOLTS AND NUTS...21
TIGHTENING TORQUE OF HOSE NUTS...22
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...22
TIGHTENING TORQUE FOR FLARED NUTS...22
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS...23
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS...23
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)...23
HOW TO READ ELECTRIC WIRE CODE...25
CONVERSION TABLES...28
METHOD OF USING THE CONVERSION TABLE...28
Millimeters to Inches...29
Kilogram to Pound...29
Liter to U.S. Gallon...30
Liter to U.K. Gallon...30
kgm to ft. lb...31
kg/cm2 to lb/in2...32
Temperature...33
COATING MATERIALS...34
01 GENERAL...37
SPECIFICATIONS...38
DIMENSIONS...39
FIXED GAUGE SPECIFICATION...39
VARIABLE GAUGE SPECIFICATION...39
WORKING RANGES...39
WEIGHT TABLE...44
FUEL COOLANT AND LUBRICANTS...46
10 STRUCTURE AND FUNCTION...49
ENGINE AND COOLING SYSTEM...53
ENGINE RELATED PARTS...53
RADIATOR, OIL COOLER AND AFTERCOOLER...54
POWER TRAIN...55
POWER TRAIN...55
FINAL DRIVE...56
SPROCKET...58
SWING MACHINERY...60
SWING CIRCLE...62
UNDERCARRIAGE AND FRAME...64
TRACK FRAME AND RECOIL SPRING...64
IDLER...66
CARRIER ROLLER...68
TRACK ROLLER...70
TRACK SHOE...72
TRIPLE GROUSER SHOE...75
HYDRAULIC SYSTEM...76
HYDRAULIC PIPING DRAWING...76
HYDRAULIC TANK AND FILTER...78
HYDRAULIC PUMP...80
LS VALVE...86
PC VALVE...91
LS(PC)-EPC VALVE...98
VARIABLE VOLUME VALVE...101
CONTROL VALVE...102
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)...114
FUNCTIONS AND OPERATION BY VALVE...118
UNLOAD VALVE...120
LS BYPASS VALVE...123
PRESSURE COMPENSATION VALVE...124
PRESSURE COMPENSATION VALVE INNER SHUTTLE VALVE...127
BOOM REGENERATION CIRCUIT...129
ARM REGENERATION CIRCUIT...131
MERGE-DIVIDER VALVE...133
LS SELECT VALVE...135
SELF PRESSURE REDUCING VALVE...136
TRAVEL JUNCTION VALVE...139
TRAVEL PPC SHUTTLE VALVE...141
BOOM DRIFT PREVENTIVE VALVE...143
ARM DRIFT PREVENTIVE VALVE...146
QUICK RETURN VALVE...150
LIFT CHECK VALVE...152
MAIN RELIEF VALVE...153
2-STAGE SAFETY-SUCTION VALVE...154
VARIABLE PRESSURE COMPENSATION VALVE...156
ATTACHMENT CIRCUIT SELECTOR VALVE...162
VALVE CONTROL...160
PPC VALVE...162
TRAVEL PPC VALVE...167
SERVICE PPC VALVE...177
SOLENOID VALVE...179
PPC ACCUMULATOR...181
RETURN OIL FILTER...182
CENTER SWIVEL JOINT...183
TRAVEL MOTOR...185
BRAKE VALVE...193
SWING MOTOR...199
REVERSE PREVENTION VALVE...205
WORK EQUIPMENT...211
WORK EQUIPMENT...211
DIMENSIONS OF COMPONENTS...213
DIMENSION OF ARM...213
DIMENSION OF BUCKET...215
AIR CONDITIONER PIPING...217
ELECTRICAL SYSTEM...218
ENGINE CONTROL...218
FUEL CONTROL DIAL...219
ENGINE CONTROLLER...221
SENSORS...225
ROTATION SENSOR...225
OIL PRESSURE SWITCH...225
AMBIENT PRESSURE SENSOR...226
BOOST PRESSURE SENSOR...226
BOOST TEMPERATURE SENSOR...227
COOLANT TEMPERATURE SENSOR...227
HYDRAULIC OIL TEMPERATURE SENSOR...227
EGR VALVE STROKE SENSOR...228
ENGINE OIL LEVEL SENSOR...229
ELECTRONIC CONTROL SYSTEM...230
ENGINE AND PUMP COMPOSITE CONTROL FUNCTION...233
PUMP AND VALVE CONTROL FUNCTION...238
POWER MAXIMIZING AND MACHINE PUSH-UP FUNCTION...240
AUTO-DECELERATION FUNCTION...242
AUTO-WARM-UP AND OVERHEAT PREVENTION FUNCTION...243
SWING CONTROL FUNCTION...245
TRAVEL CONTROL FUNCTION...247
ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR FUNCTION...249
SYSTEM COMPONENT PARTS...250
PUMP PRESSURE SENSOR (HIGH PRESSURE)...252
PUMP CONTROLLER...253
MONITOR SYSTEM...256
MACHINE MONITOR...257
MONITOR PORTION...259
SWITCHES...264
MAINTENANCE FUNCTION...271
SENSOR...277
HYDRAULIC OIL LEVEL SENSOR...277
HYDRAULIC OIL TEMPERATURE SENSOR...277
COOLANT TEMPERATURE SENSOR...277
FUEL LEVEL SENSOR...278
AIR CLEANER CLOGGING SENSOR...278
KOMTRAX TERMINAL SYSTEM...280
KOMTRAX TERMINAL...281
20 TESTING, ADJUSTING AND TROUBLESHOOTING...283
STANDARD VALUE TABLES...284
ENGINE RELATED...284
TESTING AND ADJUSTING...293
SERVICE TOOLS...295
ENGINE SPEED...297
ENGINE...298
EXHAUST GAS COLOR...299
FAN BELT AND ALTERNATOR BELT TENSION...300
AIR CONDITIONER COMPRESSOR BELT TENSION...301
SWING CIRCLE BEARING CLEARANCE...302
TRACK SHOE TENSION...303
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS...304
CONTROL CIRCUIT - BASIC PRESSURE...309
PUMP PC CONTROL CIRCUIT...310
PUMP LS CONTROL CIRCUIT...314
SOLENOID VALVE - OUTPUT PRESSURE...319
PPC VALVE - OUTPUT PRESSURE...322
WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT...324
SWING PPC VALVE - PLAY ADJUSTMENT...324
WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE...325
RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT...327
MEASURING OIL LEAKAGE...328
BLEEDING AIR FROM VARIOUS PARTS...331
DIODE TESTING PROCEDURE...334
MONITOR PANEL - SPECIAL FUNCTIONS...335
OPERATOR?S MENU (OUTLINE)...337
FAILURE CODES TABLE...343
SERVICE MENU...346
LIST OF MONITORING ITEMS...349
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER...363
PROCEDURE FOR TURNING ON KOMTRAX TERMINAL...364
ELECTRICAL EQUIPMENT SYSTEM - PREPARATION WORK FOR TROUBLESHOOTING...370
12 PM CLINIC SERVICE...372
TROUBLESHOOTING GENERAL...379
POINTS TO REMEMBER WHEN TROUBLESHOOTING...381
SEQUENCE OF EVENTS IN TROUBLESHOOTING...383
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...384
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT...384
HANDLING WIRING HARNESSES AND CONNECTORS...384
12 REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES...386
HANDLING CONTROL BOX...389
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS...390
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...390
CHECKS BEFORE TROUBLESHOOTING...392
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING...393
CLASSIFICATION OF TROUBLESHOOTING...393
STEPS FOR TROUBLESHOOTING...393
POSSIBLE PROBLEMS AND TROUBLESHOOTING NO...394
CONNECTOR ARRANGEMENT DIAGRAM...397
ELECTRICAL CIRCUIT DIAGRAM...408
See Section 90 for diagrams...408
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...409
12 T-BOXES AND T-ADAPTERS TABLE...431
TROUBLESHOOTING ERROR CODES AND FAILURE CODES...435
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...439
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF...440
USER CODE MEMORY RETENTION FUNCTION...440
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...441
FAILURE CODES TABLE...441
BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS DISPLAYED...444
INFORMATION IN TROUBLESHOOTING TABLE...448
A000N1 - ENG. HI OUT OF STD...450
AA10NX - AIR CLEANER CLOGGING...451
AB00KE - CHARGE VOLTAGE LOW...452
B@BAZG - ENG OIL PRESS. LOW...454
B@BAZK - ENG. OIL LEVEL LOW...456
B@BCZK - ENG. WATER LVL LOW...460
B@HANS - HYD. OIL OVERHEAT...461
CA111 - ECM CRITICAL INTERNAL FAILURE...462
CA115 - ENG NE AND BKUP SPEED SENS ERROR...464
CA122 - CHG AIR PRESS SENSOR HIGH ERROR...466
CA123 - CHG AIR PRESS SENSOR LOW ERROR...468
CA131 - THROTTLE SENSOR HIGH ERROR...470
CA132 - THROTTLE SENSOR LOW ERROR...471
CA135 - ENG OIL PRESS SENSOR HIGH ERROR...472
CA141 - ENG OIL PRESS SENSOR LOW ERROR...473
CA144 - COOLANT TEMP SENS HIGH ERROR...474
CA145 - COOLANT TEMP SENS LOW ERROR...475
CA153 - CHG AIR TEMP SENSOR HIGH ERROR...476
CA154 - CHG AIR TEMP SENSOR LOW ERROR...478
CA187 - SENS SUPPLY 2 VOLT LOW ERROR...479
CA221 - AMBIENT PRESS SENS HIGH ERROR...480
CA222 - AMBIENT PRESS SENS LOW ERROR...482
CA227 - SENS SUPPLY 2 VOLT HIGH ERROR...484
CA234 - ENG OVERSPEED...486
CA238 - NE SPEED SENS SUPPLY VOLT ERROR...488
CA263 - FUEL TEMP SENSOR HIGH ERROR...490
CA265 - FUEL TEMP SENSOR LOW ERROR...492
CA271 - IMV/PCV1 SHORT ERROR...493
CA272 - IMV/PCV1 OPEN ERROR...494
CA273 - PCV2 SHORT ERROR...496
CA274 - PCV2 OPEN ERROR...497
CA322 - INJ #1 (L#1) OPEN/SHORT ERROR...498
CA323 - INJ #5 (L#5) OPEN/SHORT ERROR...499
CA324 - INJ #3 (L#3) OPEN/SHORT ERROR...500
CA325 - INJ #6 (L#6) OPEN/SHORT ERROR...501
CA331 - INJ #2 (L#2) OPEN/SHORT ERROR...502
CA332 - INJ #4 (L#4) OPEN/SHORT ERROR...503
CA342 - CALIBRATION CODE INCOMPATIBILITY...504
CA351 - INJECTORS DRIVE CIRCUIT ERROR...506
CA352 - SENS SUPPLY 1 VOLT LOW ERROR...508
CA386 - SENS SUPPLY 1 VOLT HIGH ERROR...510
CA441 - BATTERY VOLTAGE LOW ERROR...512
CA442 - BATTERY VOLTAGE HIGH ERROR...513
CA449 - RAIL PRESS VERY HIGH ERROR...514
CA451 - RAIL PRESS SENSOR HIGH ERROR...516
CA452 - RAIL PRESS SENSOR LOW ERROR...518
CA553 - RAIL PRESS HIGH ERROR 1...518
CA554 - RAIL PRESS SENSOR IN RANGE ERROR...519
CA559 - RAIL PRESS LOW ERROR...520
CA689 - ENG NE SPEED SENSOR ERROR...524
CA731 - ENG BKUP SPEED SENS PHASE ERROR...526
CA757 - ALL PERSISTENT DATA LOST ERROR...527
CA778 - ENG BKUP SPEED SENSOR ERROR...528
CA1228 - EGR VALVE SERVO ERROR 1...530
CA1625 - EGR VALVE SERVO ERROR 2...531
CA1633 - KOMNET DATALINK TIMEOUT ERROR...532
CA2185 - THROT SENS SUP VOLT HIGH ERROR...534
CA2186 - THROT SENS SUP VOLT LOW ERROR...536
CA2249 - RAIL PRESS VERY LOW ERROR...537
CA2271 - EGR VALVE LIFT SENS HIGH ERROR...538
CA2272 - EGR VALVE LIFT SENS LOW ERROR...540
CA2351 - EGR VALVE SOL CURRENT HIGH ERROR...542
CA2352 - EGR VALVE SOL CURRENT LOW ERROR...544
CA2555 - GRID HTR RELAY VOLT LOW ERROR...545
CA2556 - GRID HTR RELAY VOLT HIGH ERROR...546
D110KB - BATTERY RELAY DRIVE S/C...548
D196KA - SERVICE RETURN RELAY DISC...550
D196KB - SERVICE RETURN RELAY S/C...552
DA25KP - PRESS. SENSOR POWER ABNORMALITY...554
DA80MA - AUTO-LUBE ABNORMAL...556
DA2RMC - PUMP COMM. ABNORMALITY...558
DA2SKQ - MODEL SELECTION ABNORMALITY...560
DAFRMC - MONITOR COMM. ABNORMALITY...562
DHPAMA - F PUMP P. SENSOR ABNORMALITY...564
DHPBMA - R PUMP P. SENSOR ABNORMALITY...566
DHS3MA - ARM CURL PPC SEN. ABNORMALITY...568
DHS4MA - BUCKET CURL PPC SEN. ABNORMALITY...570
DW43KA - TRAVEL SPEED SOL. DISC...572
DW43KB - TRAVEL SPEED SOL. S/C...574
DW45KA - SWING BRAKE SOL. DISC...576
DW45KB - SWING BRAKE SOL. S/C...578
DW91KA - TRAVEL JUNCTION SOL. DISC...580
DW91KB - TRAVEL JUNCTION SOL. S/C...582
DWJ0KA - MERGE-DIVIDER SOL. DISC...584
DWJ0KB - MERGE-DIVIDER SOL. S/C...586
DWK0KA - 2-STAGE RELIEF SOL. DISC...588
DWK0KB - 2-STAGE RELIEF SOL. S/C...590
DXA0KA - PC-EPC SOL. DISC...592
DXA0KB - PC-EPC SOL. S/C...594
DXE0KA - LS-EPC SOL. DISC...596
DXE0KB - LS-EPC SOL. S/C...598
DXE4KA - SERVICE CURRENT EPC DISC...600
DXE4KB - SERVICE CURRENT EPC S/C...601
DY20KA - WIPER WORKING ABNORMALITY...602
DY20MA - WIPER PARKING ABNORMALITY...604
DY2CKB - WASHER DRIVE S/C...606
DY2DKB - WIPER DRIVE (FOR) S/C...608
DY2EKB - WIPER DRIVE (REV) S/C...610
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...613
BEFORE CARRYING OUT TROUBLESHOOTING...614
CONNECTION TABLE OF FUSE BOX...614
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...616
E-1 ENGINE DOES NOT START...617
E-2 AUTO-DECELERATOR DOES NOT OPERATE...620
E-3 AUTOMATIC WARMING-UP DOES NOT OPERATE...621
E-4 PREHEATER DOES NOT OPERATE...622
E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE...624
E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE...626
E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL...627
E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS...628
E-9 DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINE...628
E-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE RUNNING...629
E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY...630
E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY...632
E-13 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY...633
E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY...634
E-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS NOTHING...636
E-16 WINDSHIELD WIPER DOES NOT OPERATE...638
E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY...642
E-18 MONITORING FUNCTION FAILS TO DISPLAY ?BOOM RAISE? NORMALLY...644
E-19 MONITORING FUNCTION FAILS TO DISPLAY ?BOOM LOWER" NORMALLY...645
E-20 MONITORING FUNCTION FAILS TO DISPLAY ?ARM IN? NORMALLY...646
E-21 MONITORING FUNCTION FAILS TO DISPLAY ?ARM OUT? NORMALLY...647
E-22 MONITORING FUNCTION FAILS TO DISPLAY ?BUCKET CURL" NORMALLY...648
E-23 MONITORING FUNCTION FAILS TO DISPLAY ?BUCKET DUMP" NORMALLY...649
E-24 MONITORING FUNCTION FAILS TO DISPLAY ?SWING? NORMALLY...650
E-25 MONITORING FUNCTION FAILS TO DISPLAY ?TRAVEL? NORMALLY...652
E-26 MONITORING FAILS TO DISPLAY ?TRAVEL DIFFERENTIAL PRESSURE" NORMALLY...654
E-27 MONITORING FAILS TO DISPLAY ?SERVICE? NORMALLY...656
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...658
E-29 AIR CONDITIONER DOES NOT OPERATE...660
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING...662
E-31 HORN DOES NOT SOUND...664
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H-MODE)...675
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS...676
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...678
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW...679
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS...680
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE...681
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...681
H-5 AUTO-DECELERATOR DOES NOT WORK...682
H-6 FINE CONTROL MODE DOES NOT FUNCTION...682
H-7 BOOM MOVES SLOWLY OR LACKS POWER...683
H-8 ARM MOVES SLOWLY OR LACKS POWER...684
H-9 BUCKET MOVES SLOWLY OR LACKS POWER...685
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION...685
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT...686
H-12 WORK EQUIPMENT HAS BIG TIME LAG...687
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT...687
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK...687
H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK...688
H-16 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY...688
H-17 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY...689
H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY...689
H-19 MACHINE SWERVES IN TRAVEL...690
H-20 MACHINE TRAVELS SLOWLY...691
H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER...692
H-22 TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED...693
H-23 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)...693
H-24 MACHINE DOES NOT SWING...694
H-25 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW...695
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING...696
H-27 THERE IS BIG SHOCK WHEN STOPPING SWING...697
H-28 LARGE SOUND CAUSED WHEN STOPPING SWING...697
H-29 SWING NATURAL DRIFT IS TOO LARGE...698
H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE...699
H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED...699
30 DISASSEMBLY AND ASSEMBLY...701
HOW TO READ THIS MANUAL...705
REMOVAL AND INSTALLATION OF PARTS...705
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES...707
PRECAUTIONS DURING OPERATION...709
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...709
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...710
PRECAUTIONS WHEN COMPLETING THE OPERATIONS...711
OTHER PRECAUTIONS...711
SPECIAL TOOL LIST...712
SKETCHES OF SPECIAL TOOLS...716
CONNECTOR REPAIR PROCEDURES...718
CONTACT TERMINAL REMOVAL (HD30 TYPE)...718
STRIPPING INSULATION...719
CRIMPING CONTACT TERMINAL (HD30 TYPE)...720
INSERTION OF CONTACT TERMINAL (HD30 TYPE)...721
CONTACT TERMINAL REMOVAL (DT TYPE)...722
CRIMPING CONTACT TERMINAL (DT TYPE)...723
INSERTION OF CONTACT TERMINAL (DT TYPE)...724
ENGINE...725
AFTERCOOLER...725
ALTERNATOR...725
CYLINDER HEAD...725
ENGINE FRONT SEAL...725
ENGINE OIL COOLER...725
ENGINE REAR SEAL...725
FUEL INJECTION PUMP...725
NOZZLE HOLDER...725
NOZZLE TIP...725
STARTING MOTOR...725
THERMOSTAT...725
TURBOCHARGER...725
WATER PUMP...725
RADIATOR ASSEMBLY...726
REMOVAL...726
INSTALLATION...727
HYDRAULIC OIL COOLER ASSEMBLY...728
REMOVAL...728
INSTALLATION...729
AFTERCOOLER ASSEMBLY...730
REMOVAL...730
INSTALLATION...731
ENGINE AND HYDRAULIC OIL PUMP ASSEMBLY...732
REMOVAL...732
INSTALLATION...740
FINAL DRIVE ASSEMBLY...741
DISASSEMBLY...743
REMOVAL...741
INSTALLATION...742
FINAL DRIVE ASSEMBLY...743
DISASSEMBLY...743
ASSEMBLY...747
SWING MOTOR AND SWING MACHINERY...753
DISASSEMBLY...755
REMOVAL...753
INSTALLATION...754
SWING MOTOR AND SWING MACHINERY...755
DISASSEMBLY...755
ASSEMBLY...758
SWING CIRCLE ASSEMBLY...764
REMOVAL...764
INSTALLATION...764
UNDERCARRIAGE AND FRAME...765
ASSEMBLY...765
TRACK ROLLER ASSEMBLY...767
ASSEMBLY...767
IDLER ASSEMBLY...768
DISASSEMBLY...768
ASSEMBLY...769
RECOIL SPRING ASSEMBLY...772
DISASSEMBLY...772
ASSEMBLY...773
SPROCKET...774
REMOVAL...774
INSTALLATION...774
TRACK SHOE ASSEMBLY...775
EXPANSION...775
INSTALLATION...775
REVOLVING FRAME ASSEMBLY...777
REMOVAL...777
INSTALLATION...779
COUNTERWEIGHT ASSEMBLY...780
REMOVAL...780
INSTALLATION...780
CENTER SWIVEL JOINT ASSEMBLY...781
REMOVAL...781
INSTALLATION...782
DISASSEMBLY...782
ASSEMBLY...783
HYDRAULIC TANK ASSEMBLY...784
REMOVAL...784
INSTALLATION...785
CONTROL VALVE ASSEMBLY...786
REMOVAL...786
INSTALLATION...789
DISASSEMBLY...789
REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL...789
ASSEMBLY...791
HYDRAULIC PUMP ASSEMBLY...794
REMOVAL...794
INSTALLATION...796
HYDRAULIC PUMP INPUT SHAFT...797
REMOVAL...797
INSTALLATION...797
WORK EQUIPMENT PPC VALVE ASSEMBLY...798
ASSEMBLY...798
TRAVEL PPC VALVE ASSEMBLY...799
DISASSEMBLY...799
ASSEMBLY...799
HYDRAULIC CYLINDER ASSEMBLY...800
DISASSEMBLY...800
ASSEMBLY...802
WORK EQUIPMENT ASSEMBLY...806
REMOVAL...806
INSTALLATION...807
CAB...809
REMOVAL...809
INSTALLATION...812
CAB GLASS (STUCK GLASS)...813
REMOVAL...814
INSTALLATION...814
WINDOW ASSEMBLY...824
REMOVAL...824
INSTALLATION...827
AIR CONDITIONER UNIT ASSEMBLY...832
REMOVAL...832
INSTALLATION...834
KOMTRAX TERMINAL ASSEMBLY...835
REMOVAL...835
INSTALLATION...835
MONITOR ASSEMBLY...836
REMOVAL...836
INSTALLATION...836
PUMP CONTROLLER...837
REMOVAL...837
INSTALLATION...837
90 OTHERS...839
REMOVAL...726
HYDRAULIC...841
HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 1 OF 5...841
HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 2 OF 5...842
HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 3 OF 5...843
HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 4 OF 5...844
HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 5 OF 5...845
HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 1 OF 6...846
HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 2 OF 6...847
HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 3 OF 6...848
HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 4 OF 6...849
HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 5 OF 6...850
HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 6 OF 6...851
ELECTRICAL...852
ELECTRICAL DIAGRAM - PAGE 1 OF 6 - SHEET 1 OF 4...852
ELECTRICAL DIAGRAM - PAGE 1 OF 6 - SHEET 2 OF 4...853
ELECTRICAL DIAGRAM - PAGE 1 OF 6 - SHEET 3 OF 4...854
ELECTRICAL DIAGRAM - PAGE 1 OF 6 - SHEET 4 OF 4...855
ELECTRICAL DIAGRAM - PAGE 2 OF 6 - SHEET 1 OF 1...856
ELECTRICAL DIAGRAM - PAGE 3 OF 6 - SHEET 1 OF 2...857
ELECTRICAL DIAGRAM - PAGE 3 OF 6 - SHEET 2 OF 2...858
ELECTRICAL DIAGRAM - PAGE 4 OF 6 - SHEET 1 OF 2...859
ELECTRICAL DIAGRAM - PAGE 4 OF 6 - SHEET 2 OF 2...860
ELECTRICAL DIAGRAM - PAGE 5 OF 6 - SHEET 1 OF 2...861
ELECTRICAL DIAGRAM - PAGE 5 OF 6 - SHEET 2 OF 2...862
ELECTRICAL DIAGRAM - PAGE 6 OF 6 - SHEET 1 OF 2...863
ELECTRICAL DIAGRAM - PAGE 6 OF 6 - SHEET 2 OF 2...864
ELECTRICAL CONNECTORS LEGEND AND LOCATION - SHEET 1 OF 9...865
ELECTRICAL CONNECTORS - SHEET 2 OF 9...866
ELECTRICAL CONNECTORS - SHEET 3 OF 9...867
ELECTRICAL CONNECTORS - SHEET 4 OF 9...868
ELECTRICAL CONNECTORS - SHEET 5 OF 9...869
ELECTRICAL CONNECTORS - SHEET 6 OF 9...870
ELECTRICAL CONNECTORS - SHEET 7 OF 9...871
ELECTRICAL CONNECTORS - SHEET 8 OF 9...872
ELECTRICAL CONNECTORS - SHEET 9 OF 9...873
MAIN MENU...0
COVER...1
INTRODUCTION...3
FOREWORD...4
SAFETY INFORMATION...5
INTRODUCTION...6
INTENDED USE...6
FEATURES...6
DIRECTIONAL REFFERENCE OF MACHINE...6
BREAKING IN A NEW MACHINE...7
PLATE LOCATIONS...7
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE...7
ENGINE SERIAL NUMBER PLATE...8
SERVICE METER LOCATION...8
TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR...9
TABLE OF CONTENTS...10
SAFETY...21
SAFETY AND WARNING DECALS...22
LOCATION OF THE SAFETY DECALS...22
SAFETY LABELS...23
OPTIONAL SYSTEMS DECAL...29
GENERAL SAFETY RULES AND PRECAUTIONS...32
GENERAL SAFETY RULES...32
UNAUTHORIZED MODIFICATIONS...33
GENERAL SAFETY AT JOB SITE...33
WORKING ON LOOSE GROUND...33
SAFETY FEATURES...34
PERSONAL PROTECTIVE EQUIPMENT...34
FIRE AND EXPLOSION PREVENTION...35
FIRE CAUSED BY FUEL OR OIL...35
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL...35
FIRE COMING FROM ELECTRIC WIRING...35
FIRE COMING FROM HYDRAULIC LINE...36
WINDSHIELD WASHER FLUID...36
ACTION IF FIRE OCCURS...36
DUST HAZARD PRECAUTIONS...36
ASBESTOS HAZARD ALERT...37
KEEP OPERATOR'S COMPARTMENT CLEAN...37
LEAVING OPERATOR'S SEAT WITH LOCK...37
MOUNTING AND DISMOUNTING...38
FIRE EXTINGUISHER AND FIRST AID KIT...38
INSIDE OPERATOR?S COMPARTMENT...39
PROTECTION AGAINST FALLING OR FLYING OBJECTS...39
PRECAUTIONS FOR ATTACHMENTS...40
QUICK COUPLER ATTACHMENT...40
LARGE ATTACHMENTS AND COMBINATIONS...40
PRECAUTIONS BEFORE STARTING OPERATIONS...41
PRE-OPERATIONAL CHECKS...41
STARTING YOUR WORK OPERATIONS...41
WORK SITE HAZZARDS...42
AVOIDING DANGEROUS SITUATIONS...42
DIGGING HARD ROCKY GROUND...46
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL...46
WORKING CLEARANCES...46
OPERATIONS ON SLOPES...47
OPERATIONS ON SNOW...47
RULES FOR ROAD TRAVEL...48
TRAVELING WITH CARRAGE REVERSED...48
TRAVEL ON SLOPES...49
PARKING THE MACHINE...50
PRECAUTIONS DURING MAINTENANCE OPERATIONS...51
WARNING TAGS...51
EQUIPMENT STORAGE...51
WORKING UNDER THE MACHINE...52
USING DROP LAMPS...52
KEEPING THE MACHINE CLEAN...52
PERFORMING GENERAL MAINTENANCE PROCEDURES...53
RUNNING THE ENGINE DURING MAINTENANCE...54
PROPER TOOLS...54
WELDING, GRINDING OR CUTTING...55
ADJUSTING TRACK TENSION...55
DO NOT DISASSEMBLE RECOIL SPRINGS...55
WHEN USING HAMMER...55
RULES FOR REFUELING THE MACHINE...56
COOLING SYSTEM PRECAUTIONS...56
BATTERY PRECAUTIONS...57
STARTING ENGINE WITH BOOSTER CABLES...57
STARTING PRECAUTIONS...57
HIGH PRESSURE HOSES...58
SAFETY HANDLING HIGH-PRESSURE HOSES...58
PRECAUTION FOR HIGH FUEL PRESSURE...58
HIGH TEMPERATURES AREAS...58
DISPOSAL OF WASTE MATERIALS...59
ACCUMULATOR...59
CRITICAL PARTS...59
HIGH VOLTAGE...60
TOWING...60
SAFETY RULES FOR TOWING...60
OPERATION...61
GENERAL VIEWS...62
VIEW OF MACHINE...62
VIEW CONTROLS AND GAUGES...63
MACHINE MONITOR SYSTEM...64
MONITOR BEZEL LAYOUT...64
BASIC OPERATION OF MACHINE MONITOR...65
ABNORMALITY OCCURS WHEN STARTING THE ENGINE...66
ABNORMALITY OCCURS DURING OPERATION...67
COLOR WARNING OR ALERT SYSTEM...68
MONITOR CHECK ITEMS...69
EMERGENCY ALERTS...69
ENGINE COOLANT TEMPERATURE MONITOR...69
HYDRAULIC OIL TEMPERATURE MONITOR...70
ENGINE OIL PRESSURE MONITOR...70
WARNING ALERTS...71
ENGINE COOLANT TEMPERATURE MONITOR...71
HYDRAULIC OIL TEMPERATURE MONITOR...72
FUEL LEVEL MONITOR...72
CHARGE MONITOR...72
AIR CLEANER CLOGGING MONITOR...72
CHECK ALERTS...73
COOLANT LEVEL MONITOR...73
ENGINE OIL LEVEL MONITOR...74
MAINTENANCE INTERVAL MONITOR...74
METER DISPLAY...75
PILOT DISPLAYS...75
GAUGES...78
MONITOR SWITCHES...80
SWITCH LAYOUT VIEW...80
WORKING MODE SELECTOR SWITCH...81
AUTO-DECELERATION SWITCH...82
TRAVEL SPEED SELECTOR SWITCH...83
WIPER SWITCH...84
WINDOW WASHER SWITCH...84
MAINTENANCE SWITCH...85
SELECT SWITCH...87
BACK SWITCH...89
UP SWITCH, DOWN SWITCH...89
INPUT CONFIRMATION SWITCH...90
LIQUID CRYSTAL ADJUSTMENT SWITCH...90
ALARM BUZZER STOP SWITCH...91
CONSOLE CONTROL SWITCHES...92
SWITCH LAYOUT VIEW...92
IGNITION SWITCH...93
ENGINE SPEED CONTROL DIAL...93
CIGARETTE LIGHTER...93
SWING LOCK SWITCH...94
LAMP SWITCH...94
MACHINE PUSH-UP SWITCH...94
HORN SWITCH...95
POWER MAX SWITCH...95
CAB LAMP SWITCH...95
EMERGENCY PUMP DRIVE SWITCH...96
SWING BRAKE CANCEL SWITCH...96
CONTROL LEVERS AND PEDALS...97
LEVER LAYOUT VIEW...97
SAFETY LOCK LEVER...97
TRAVEL LEVERS...98
WORK EQUIPMENT CONTROL LEVER...99
WINDOW SYSTEM...100
CEILING WINDOW...100
WHEN OPENING...100
WHEN CLOSING...100
FRONT WINDOW...101
WHEN OPENING...101
WHEN CLOSING...103
REMOVING FRONT BOTTOM WINDOW...105
CAB EMERGENCY EXIT WINDOW...105
SAFETY LOCKS AND SECURITY...106
DOOR LOCK...106
CAP, COVER WITH LOCK...106
OPENING AND CLOSING CAP WITH LOCK...107
OPENING AND CLOSING COVER...107
LOCKABLE AREAS...107
ADDTIONAL FEATURES AND ACCESSORIES...109
HOT AND COOL BOX...109
STORAGE BOX WITH CUP HOLDER...109
ASHTRAY...109
AUTO-TEMP AIR CONDITIONER...110
GENERAL DESCRIPTION OF CONTROL PANEL...110
SUNLIGHT SENSOR...114
A/C SYSTEM OPERATION...114
PRECAUTIONS WHEN USING AIR CONDITIONER...121
MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER...121
SELF-DIAGNOSTIC FUNCTION...121
RADIO...123
EXPLANATION OF FEATURES...123
CONTROLS ON RADIO...125
TOOLBOX...127
GREASE GUN HOLDER...127
AUXILIARY POWER PORTS...127
24V POWER SOURCE...127
12V POWER SOURCE (IF EQUIPPED)...127
FUSES AND FUSE LINKS...128
FUSES...128
FUSE CAPACITIES AND CIRCUIT NAMES...128
FUSIBLE LINK...129
CONTROLLER...129
PRECAUTIONS BEFORE STARTING WORK OPERATIONS...130
PRE-OPERATIONAL CHECKS...130
WALK-AROUND CHECKS...130
CHECKS BEFORE STARTING...131
ADJUSTMENTS BEFORE OPERATION...136
REARVIEW MIRRORS...137
VISIBILITY FROM OPERATORS SEAT...138
SEAT BELT...139
SYSTEM ?ON? CHECKS...139
STARTING THE ENGINE...142
NORMAL OR COLD START PROCEDURES...142
OPERATIONS AND CHECKS AFTER STARTING ENGINE...145
BREAKING IN THE MACHINE...145
WARMING UP ENGINE...145
WARMING UP HYDRAULIC EQUIPMENT...147
AFTER WARMING-UP OPERATIONS...151
STOPPING THE ENGINE...152
CHECK AFTER SHUTING OFF ENGINE...152
MOVING, STOPPING AND PARKING THE MACHINE...153
PREPARATIONS FOR MOVING THE MACHINE...153
MOVING MACHINE FORWARD...154
MOVING MACHINE BACKWARD...155
STOPPING MACHINE...156
TURNING THE MACHINE...157
TURNING THE MACHINE WHEN STOPPED...157
CHANGING DIRECTION OF THE MACHINE...158
COUNTER-ROTATION TURN (SPIN TURN)...158
SWINGING...159
GENERAL TRAVELING...160
TRAVELING OVER OBSTACLES...160
HIGH SPEED TRAVEL...160
PERMISSIBLE WATER DEPTH...160
TRAVELING ON SLOPES...161
TRAVELING DOWNHILL...162
ENGINE STOPPED ON SLOPE...162
PRECAUTIONS ON SLOPES...162
ESCAPING FROM MUD...163
ONE SIDE OF TRACK STUCK...163
BOTH SIDES OF TRACKS STUCK...163
PARKING MACHINE...164
CLEARING THE MACHINES TRACKS...164
PARKING...164
MACHINE INSPECTION AFTER DAILY WORK...166
STARTING YOUR WORK OPERATIONS...167
AVOIDING DANGEROUS SITUATIONS...167
DIGGING HARD ROCKY GROUND...170
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL...170
WORKING CLEARANCES...171
OPERATIONS ON SLOPES...171
OPERATIONS ON SNOW...172
WORK EQUIPMENT OVERVIEW...173
ARM CONTROL...173
SWING CONTROL...173
BOOM CONTROL...173
BUCKET CONTROL...173
OPERATING MODES...174
WORKING MODE...174
ONE-TOUCH POWER MAX. SWITCH...174
EXCAVATING PROCEDURES...175
WORK EQUIPMENT ANGLES...176
DITCHING WORK...176
LOADING WORK...176
SEVERE JOB CONDITIONS...176
BUCKET REPLACEMENT AND INVERSION...177
BUCKET REPLACEMENT...177
BUCKET INVERSION...178
TRANSPORTING THE MACHINE...179
LOADING AND UNLOADING A TRAILER...179
LOADING THE MACHINE...180
SECURING MACHINE...182
UNLOADING THE MACHINE...183
LIFTING THE MACHINE...185
DISSEMBLY TRANSPORTATION POSTURE...187
POSTURE FOR EACH PART...187
TOWING THE MACHINE...190
LIGHTWEIGHT TOWING HOOK...191
SEVERE JOB CONDITION...191
INCREASING OR REDUCING TRACK FRAME GAUGE...192
REDUCING TRACK GAUGE...192
INCREASING TRACK GAUGE...193
COLD WEATHER OPERATION...194
FUEL AND LUBRICANTS...194
COOLING SYSTEM COOLANT...194
BATTERY...195
MONITOR...196
PRECAUTIONS ON PARTICULAR JOBSITES...197
DISCHARGED BATTERY...197
REMOVAL AND INSTALLATION OF BATTERY...198
BATTERY CHARGES...198
STARTING ENGINE WITH BOOSTER CABLES...199
GENERAL TROUBLESHOOTING...201
AFTER RUNNING OUT OF FUEL...201
PROCEDURE FOR BLEEDING AIR...201
PHENOMENA THAT ARE NOT FAILURES...202
ELECTRICAL SYSTEM PROBLEMS...203
CHASSIS PROBLEMS...204
ENGINE PROBLEMS...205
ELECTRONIC CONTROL SYSTEM...206
MACHINE MONITOR TROUBLE DISPLAY...206
TELEPHONE WHEN ERROR OCCURS...207
LONG TERM STORAGE...208
BEFORE STORAGE...208
DURING STORAGE...208
AFTER STORAGE...208
STARTING MACHINE...208
MAINTENANCE...209
MAINTENANCE INFORMATION...210
SERVICE METER READING...210
KOMATSU GENUINE REPLACEMENT PARTS...210
KOMATSU GENUINE LUBRICANTS...210
WINDSHIELD WASHER FLUID...210
FRESH AND CLEAN LUBRICANTS...210
CHECK DRAINED OIL AND USED FILTER...210
FUEL STRAINER...210
WELDING INSTRUCTIONS...210
DO NOT DROP THINGS INSIDE MACHINE...210
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE...210
DUSTY JOBSITE...211
AVOID MIXING LUBRICANTS...211
LOCKING THE INSPECTION COVERS...211
HYDRAULIC SYSTEM - AIR BLEEDING...211
HYDRAULIC HOSE INSTALLATION...211
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS...211
LUBRICANTS, COOLANT AND FILTERS...212
OUTLINE OF SERVICE...212
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...212
OIL...212
FUEL...213
COOLING SYSTEM COOLANT...213
GREASE...213
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)...214
OIL AND FUEL STORAGE...214
FILTERS...215
ELECTRIC SYSTEM MAINTENANCE...216
HANDLING HYDRAULIC SYSTEM...216
WEAR PARTS LIST...217
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...218
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS...220
TIGHTENING TORQUE SPECIFICATIONS...221
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...222
SAFETY RELATED CRITICAL PARTS...223
MAINTENANCE SCHEDULE...224
MAINTENANCE SCHEDULE CHART...224
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER...226
REPLACE HYDRAULIC FILTER ELEMENT...226
CHANGE OIL IN HYDRAULIC TANK...226
REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER (IF EQUIPPED)...226
MAINTENANCE PROCEDURE...227
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)...227
WHEN REQUIRED...228
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...228
CLEAN INSIDE OF COOLING SYSTEM...233
CHECK AND TIGHTEN TRACK SHOE BOLTS...236
CHECK AND ADJUST TRACK TENSION...237
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...239
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...242
REPLACE BUCKET SIDE CUTTER, SHROUD...243
ADJUST BUCKET CLEARANCE...244
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...245
CHECK AND ADJUST AIR CONDITIONER...245
CLEANING CAB FLOOR...246
SETTING MACHINE AT AN ANGLE...248
BLEEDING AIR FROM HYDRAULIC SYSTEM...249
CHECK BEFORE STARTING...251
EVERY 50 HOURS MAINTENANCE...252
LUBRICATING...252
EVERY 250 HOURS MAINTENANCE...253
LUBRICATE SWING CIRCLE...253
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL...253
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...254
CHECK LEVEL OF BATTERY ELECTROLYTE...255
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...257
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...258
EVERY 500 HOURS MAINTENANCE...259
LUBRICATING...259
REPLACE FUEL PRE-FILTER CARTRIDGE...260
CHECK SWING PINION GREASE LEVEL, ADD GREASE...263
CHANGING ENGINE OIL AND REPLACING ENGINE OIL FILTER CARTRIDGE...264
CLEAN/INSPECT RADIATOR, OIL COOLER, AFTERCOOLER AND CONDENSER FINS...265
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS...266
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK...267
EVERY 1000 HOURS MAINTENANCE...268
REPLACE FUEL MAIN FILTER CARTRIDGE...268
REPLACE HYDRAULIC OIL FILTER ELEMENT...270
CHANGE OIL IN SWING MACHINERY CASE...271
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL...272
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS...272
REPLACE CORROSION RESISTOR CARTRIDGE (IF EQUIPPED)...273
CHECK FAN BELT AND ALTERNATOR DRIVE BELT TENSION, REPLACE...273
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT...274
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)...274
EVERY 2000 HOURS MAINTENANCE...275
CHANGE OIL IN FINAL DRIVE CASE...275
CLEAN HYDRAULIC TANK STRAINER...276
CHECKING CHARGE PRESSURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)...277
CHECKING FUNCTION OF ACCUMULATOR...278
RELEASING PRESSURE IN HYDRAULIC CIRCUIT...279
CHECK ALTERNATOR, STARTING MOTOR...280
CHECK ENGINE VALVE CLEARANCE, ADJUST...280
CHECK VIBRATION DAMPER...280
EVERY 4000 HOURS MAINTENANCE...281
CHECK WATER PUMP...281
CHECKING CHARGE PRESSURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)...281
CHECK HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER...282
CHECK FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...282
EVERY 5000 HOURS MAINTENANCE...283
CHANGE OIL IN HYDRAULIC TANK...283
EVERY 8000 HOURS MAINTENANCE...284
REPLACE HIGH-PRESSURE PIPING CLAMP...284
REPLACE FUEL SPRAY PREVENTION CAP...284
SPECIFICATIONS...285
SPECIFICATIONS...286
OPTIONS, ATTACHMENTS...289
GENERAL PRECAUTIONS...290
PRECAUTIONS RELATED TO SAFETY...290
PRECAUTIONS FOR ATTACHMENT REMOVAL AND INSTALLATION...290
PRECAUTIONS WHEN USING LARGE IMPLEMENTS...291
HANDLING BUCKET WITH HOOK...292
HOOK CONDITION...292
PROHIBITED OPERATIONS...292
MACHINES READY FOR ATTACHMENTS...293
EXPLANATION OF COMPONENTS...293
STOP VALVE...293
SELECTOR VALVE...294
ATTACHMENT CONTROL PEDAL...294
LOCK PIN...295
BREAKER CIRCUIT ADDITIONAL OIL FILTER...295
HYDRAULIC CIRCUIT...298
SWITCHING THE HYDRAULIC CIRCUIT...298
ADJUSTING OIL FLOW...298
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT...298
HYDRAULIC CIRCUIT CONNECTION...299
OIL FLOW...300
REPLACE ADDITIONAL BREAKER FILTER ELEMENT...301
ATTACHMENT INSTALLATION AND REMOVAL PROCEDURE...302
REMOVAL PROCEDURE...302
INSTALLATION PROCEDURE...303
ATTACHMENT OPERATIONS...304
WHEN USING BREAKER...304
WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER...304
LONG TERM STORAGE...305
SPECIFICATIONS...305
ATTACHMENT GUIDE...306
COMBINATIONS OF WORK EQUIPMENT...306
SELECTION OF TRACK SHOES...308
SELECTING SHOES...308
HYDRAULIC BREAKER...309
MAIN APPLICATIONS...309
PROHIBITED OPERATIONS...310
GREASING...312
